Dry formed composite with cut and place layers

Abstract

The present invention generally relates to a method and apparatus for forming an absorbent garment and an absorbent composite core. The absorbent composite core preferably is comprised of at least four layers, whereby two of the layers are outer layers, (an upper layer and a lower layer), one of the inner layers is a central fibrous layer containing a mixture of tow fibers and SAP, and the other inner layer is at least one layer selected from an acquisition layer, a distribution layer, an additional fibrous layer optionally containing SAP, a wicking layer, a storage layer, a dryness layer, a softness layer, or combinations and fragments thereof.

What is claimed is:  
     
       1. A method of making an absorbent composite core comprising: 
       providing an upper layer to a core forming station;  
       providing a lower layer to a core forming station;  
       providing at least one additional layer;  
       cutting the at least one additional layer and placing it on a surface of the upper layer or lower layer prior to forming the core; and  
       forming the absorbent composite core at the core forming station by forming a central fibrous layer comprising a mixture of tow fibers and superabsorbent polymer material (SAP) and disposing the central fibrous layer between the upper layer and the lower layer so that it contacts the at least one additional layer.  
     
     
       2. The method of  claim 1 , wherein the at least one additional layer is selected from the group consisting of a fluid acquisition layer, a distribution layer, an additional fibrous layer optionally containing SAP, a wicking layer, a storage layer, a dryness layer, a softness layer, and combinations and fragments thereof. 
     
     
       3. The method of  claim 1 , wherein one additional layer is used, and the layer is a fluid acquisition layer. 
     
     
       4. The method of  claim 1 , wherein one additional layer is used, and the layer is a distribution layer. 
     
     
       5. The method of  claim 1 , wherein one additional layer is used, and the layer is an additional fibrous layer containing SAP. 
     
     
       6. The method of  claim 1 , wherein one additional layer is used, and the layer is a wicking layer. 
     
     
       7. The method of  claim 1 , wherein one additional layer is used, and the layer is a storage layer. 
     
     
       8. The method of  claim 1 , wherein one additional layer is used, and the layer is a fragmented layer. 
     
     
       9. The method of  claim 1 , wherein one additional layer is used, and the layer is a combination of a wicking layer and a distribution layer. 
     
     
       10. The method of  claim 1 , wherein two additional layers are used. 
     
     
       11. The method of  claim 1 , wherein the central fibrous layer comprises from about 30% to about 95% by weight super absorbent polymer (SAP). 
     
     
       12. The method of  claim 1 , wherein the central fibrous layer comprises cellulose ester tow fibers. 
     
     
       13. The method of  claim 12 , wherein the tow fibers are cellulose acetate tow fibers. 
     
     
       14. The method of  claim 1 , wherein the upper and lower layer are comprised of the same material, and the material is selected from the group consisting of tissue, airlaid fluff pulp, synthetic non-woven material, and mixtures or combinations thereof. 
     
     
       15. The method of  claim 14 , wherein the upper layer is fluid pervious, and the lower layer is fluid impervious. 
     
     
       16. The method of  claim 1 , wherein the central fibrous layer further comprises up to 10% by weight fluff wood pulp fibers. 
     
     
       17. The method of  claim 1 , wherein the central fibrous layer further comprises particulate additives. 
     
     
       18. The method of  claim 1 , wherein the at least one additional layer is provided prior to cutting at a first speed, and the upper layer or lower layer are provided to the core forming station at a second speed, the second speed being different from the first speed. 
     
     
       19. The method of  claim 18 , wherein the second speed is faster than the first speed. 
     
     
       20. A method of making an absorbent article comprising: 
       a) providing a top sheet and a back sheet to a garment forming station;  
       b) preparing an absorbent composite core by:  
       b1) providing an upper layer to a core forming station;  
       b2) providing a lower layer to a core forming station;  
       b3) providing at least one additional layer;  
       b4) cutting the at least one additional layer and placing it on a surface of the upper layer or lower layer prior to forming the core; and  
       b5) forming the absorbent composite core at the core forming station by forming a central fibrous layer comprising a mixture of tow fibers and superabsorbent polymer material (SAP) and disposing the central fibrous layer between the upper layer and the lower layer so that it contacts the at least one additional layer;  
       c) providing the absorbent composite core to the garment forming station; and  
       d) disposing the absorbent composite core between the top sheet and the back sheet at the garment forming station.  
     
     
       21. The method of  claim 20 , whereby the absorbent garment is prepared such that the top sheet and the back sheet form a first waist region, a second waist region longitudinally opposite the first waist region, and a crotch region between the waist regions. 
     
     
       22. The method of  claim 21 , further comprising 
       e) attaching at least one fastening element to lateral edges of the first waist region; and  
       f) preparing at least one target device and attaching the at least one target device to the article in the second waist region, where the at least one fastening element and the at least one target device are capable of attaching to one another, the at least one target device being located so that the first waist region and second waist region of the article may be joined to one another to secure the article on a wearer.  
     
     
       23. The method of  claim 22 , wherein the at least one fastening element comprises a hook portion of a hook and loop fastener and the at least one target device comprises the loop portion of a hook and loop fastener. 
     
     
       24. The method of  claim 22 , wherein the at least one fastening element is an adhesive tape and the at least one target device comprises a tape receiving surface. 
     
     
       25. The method of  claim 22 , wherein the at least one fastening element is comprised of a pair of laterally extending tabs disposed on the lateral edges of the first waist region, whereby the laterally extending tabs each include at least one fastening element. 
     
     
       26. The method of  claim 20 , wherein the at least one additional layer is selected from the group consisting of a fluid acquisition layer, a distribution layer, an additional fibrous layer optionally containing SAP, a wicking layer, a storage layer, a dryness layer, a softness layer, and combinations and fragments thereof. 
     
     
       27. The method of  claim 20 , wherein one additional layer is used, and the layer is a fluid acquisition layer. 
     
     
       28. The method of  claim 20 , wherein one additional layer is used, and the layer is a distribution layer. 
     
     
       29. The method of  claim 20 , wherein one additional layer is used, and the layer is an additional fibrous layer containing SAP. 
     
     
       30. The method of  claim 20 , wherein one additional layer is used, and the layer is a wicking layer. 
     
     
       31. The method of  claim 20 , wherein one additional layer is used, and the layer is a storage layer. 
     
     
       32. The method of  claim 20 , wherein one additional layer is used, and the layer is a fragmented layer. 
     
     
       33. The method of  claim 20 , wherein one additional layer is used, and the layer is a combination of a wicking layer and a distribution layer. 
     
     
       34. The method of  claim 20 , wherein two additional layers are used. 
     
     
       35. The method of  claim 20 , wherein the central fibrous layer comprises from about 30% to about 95% by weight super absorbent polymer (SAP). 
     
     
       36. The method of  claim 20 , wherein the central fibrous layer comprises, cellulose ester tow fibers. 
     
     
       37. The method of  claim 36 , wherein the tow fibers are cellulose acetate tow fibers. 
     
     
       38. The method of  claim 20 , wherein the upper and lower layer are comprised of the same material, and the material is selected from the group consisting of tissue, airlaid fluff pulp, synthetic non-woven material, and mixtures or combinations thereof. 
     
     
       39. The method of  claim 38 , wherein the upper layer is fluid pervious, and the lower layer is fluid impervious. 
     
     
       40. The method of  claim 20 , wherein the central fibrous layer further comprises up to 10% by weight fluff wood pulp fibers. 
     
     
       41. The method of  claim 20 , wherein the central fibrous layer further comprises particulate additives. 
     
     
       42. The method of  claim 20 , wherein the at least one additional layer is provided prior to cutting at a first speed, and the upper layer or lower layer are provided to the core forming station at a second speed, the second speed being different from the first speed. 
     
     
       43. The method of  claim 42 , wherein the second speed is faster than the first speed. 
     
     
       44. An apparatus for forming an absorbent composite core comprising: 
       a composite core forming station;  
       an upper layer supply mechanism for supplying an upper layer material to the composite core forming station;  
       a lower layer supply mechanism for supplying a lower layer to the composite core forming station;  
       a central fibrous layer making device for making the central fibrous layer by mixing tow fibers and superabsorbent polymer material (SAP), and for supplying the central fibrous layer to the core forming station; and  
       a cut-and-place apparatus for effecting cutting of at least one additional layer that is supplied to the cut-and-place apparatus at a first speed, and placing the cut additional layer(s) on either the upper layer or lower layer at a second speed prior to forming the central fibrous layer,  
       whereby the respective components are positioned relative to one another such that the central fibrous layer is disposed between the upper layer and the lower layer at the core forming station and contacts the at least one additional layer. 
     
     
       45. The apparatus of  claim 44 , whereby the second speed is different from the first speed. 
     
     
       46. The apparatus of  claim 45 , wherein the second speed is faster than the first speed. 
     
     
       47. The apparatus of  claim 44 , wherein the cut-and-place apparatus comprises: 
       a feed roller system for feeding a web containing the at least one additional layer to the cut-and-place apparatus at a first speed;  
       a cutting station to cut the web containing the at least one additional layer into discrete additional layers; and  
       a rotatable vacuum transfer drum for transferring the cut discrete additional layers at a second speed and placing the discrete additional layers on either the upper layer or lower layer.  
     
     
       48. The apparatus of  claim 47 , wherein the feed roller system comprises one or more dancer rolls, edge guide rolls, and pull rolls. 
     
     
       49. The apparatus of  claim 47 , wherein the cutting station comprises a knife roller and an anvil roller. 
     
     
       50. The apparatus of  claim 47 , further comprising a controller capable of controlling the first speed and the second speed to adequately cut-and-place the at least one additional layer on the upper layer or tower layer. 
     
     
       51. The apparatus of  claim 47 , further comprising an additional layer conveyor for placing the cut discrete additional layers on either the upper layer or the lower layer. 
     
     
       52. An apparatus for forming an absorbent garxnent comprising: 
       a garment forming station;  
       a top sheet supply mechanism for supplying a top sheet material to the garment forming station;  
       a back sheet supply mechanism for supplying a back sheet material to the garment forming station;  
       an apparatus for making a composite absorbent core that comprises:  
       a composite core forming station;  
       an upper layer supply mechanism for supplying an upper layer material to the composite core forming station;  
       a lower layer supply mechanism for supplying a lower layer to the composite core forming station;  
       a central fibrous layer making device for making the central fibrous layer by mixing tow fibers and superabsorbent polymer material (SAP), and for supplying the central fibrous layer to the core forming station; and  
       a cut-and-place apparatus for effecting cutting of at least one additional layer that is supplied to the cut-and-place apparatus at a first speed, and placing the cut additional layer(s) on either the upper layer or lower layer at a second speed prior to forming the central fibrous layer;  
       whereby the respective components are positioned relative to one another such that the central fibrous layer is disposed between the upper layer and the lower layer at the core forming station and contacts the at least one additional layer; and  
       an absorbent composite core feed mechanism for feeding the absorbent composite core to the garment forming station,  
       whereby the respective components are arranged such that the absorbent composite core is disposed between the top sheet material and the back sheet material at the garment forming station. 
     
     
       53. The apparatus of  claim 52 , further comprising an elastic supply mechanism for feeding a supply of elastic material to the garment forming station. 
     
     
       54. The apparatus of  claim 52 , further comprising a mechanism for feeding a fastening element to the absorbent garment after garment forming station, and for attaching the fastening element to the absorbent garment. 
     
     
       55. The apparatus of  claim 52 , further comprising a mechanism for feeding a standing leg gather to the absorbent garment after garment forming station, and for attaching the standing leg gather to the absorbent garment. 
     
     
       56. The apparatus of  claim 52 , further comprising a mechanism for feeding a waist elastic material to the absorbent garment prior to garment forming station. 
     
     
       57. The apparatus of  claim 52 , whereby the second speed is different from the first speed. 
     
     
       58. The apparatus of  claim 57 , wherein the second speed is faster than the first speed. 
     
     
       59. The apparatus of  claim 52 , wherein the cut-and-place apparatus comprises: 
       a feed roller system for feeding a web containing the at least one additional layer to the cut-and-place apparatus at a first speed;  
       a cutting station to cut the web containing the at least one additional layer into discrete additional layers; and  
       a rotatable vacuum transfer drum for transferring the cut discrete additional layers to either the upper layer or the lower layer at a second speed.  
     
     
       60. The apparatus of  claim 59 , wherein the feed roller system comprises one or more dancer rolls, edge guide rolls, and pull rolls. 
     
     
       61. The apparatus of  claim 59 , wherein the cutting station comprises a knife roller and an anvil roller. 
     
     
       62. The apparatus of  claim 59 , further comprising a controller capable of controlling the first speed and the second speed to adequately cut-and-place the at least one additional layer on the upper layer or lower layer. 
     
     
       63. The apparatus of  claim 59 , further comprising an additional layer conveyor for placing the cut discrete additional layers on either the upper layer or the lower layer.